Gage R&R

Average & Range Method

Operator 1
Enter your data here->

Operator 2
Enter your data here->

Operator 3
Enter your data here->

Range Average
XDiff
UCL
LCL
Repeatability(EV)
Reproducibility(AV)
Gage Capability(R&R)
Spec Tolerance
Acceptability(%)

Trial 1
Trial2
Trial3
Trial4
Trial 5
Total
Average-Appraiser 1
Range1
Trial 1
Trial2
Trial3
Trial4
Trial 5
Total
Average-Appraiser 2
Range2
Trial 1
Trial2
Trial3
Trial4
Trial 5
Total
Average-Appraiser 3
Range3

1
0.2150
0.2160
0.2150
0.2160
0.2165
1.0785
0.2157
0.0015
0.2160
0.2165
0.2150
0.2160
0.2150
1.0785
0.2157
0.0015

0.0013
0.0000
0.0028
0.0000
0.0006
0.0000
0.0006
0.0050
0.11

% Using
% Using
AIAG - Automotive Industry Action Group Formula
TV
Tolerance
Equipment Variation (Repeatability)
0.0006
%EV
82.3%
68%
Appraiser Variation (Reproducibility)
0.00000

2
0.2140
0.2145
0.2140
0.2145
0.2160
1.073
0.2146
0.002
0.2170
0.2160
0.2140
0.2145
0.2140
1.0755
0.2151
0.003

3
0.2150
0.2145
0.2150
0.2145
0.2150
1.074
0.2148
0.0005
0.2155
0.2150
0.2150
0.2145
0.2150
1.075
0.215
0.001

4
0.2140
0.2150
0.2140
0.2150
0.2155
1.0735
0.2147
0.0015
0.2145
0.2155
0.2140
0.2150
0.2140
1.073
0.2146
0.0015

Part Number
5
0.2165
0.2160
0.2165
0.2160
0.2150
1.08
0.216
0.0015
0.2150
0.2150
0.2165
0.2160
0.2165
1.079
0.2158
0.0015

6
0.2145
0.2155
0.2145
0.2155
0.2150
1.075
0.215
0.001
0.2160
0.2150
0.2145
0.2155
0.2145
1.0755
0.2151
0.0015

Constants
3 Trials
2 Trials
# Trials
2.11
2.28
2.58
3.27
0
0
0
0
0.577
0.729
1.023
1.88
0.4299
0.4857
0.5908
0.8862
0.7071
0.5231
2 Ops
3 Operators
5 Trials

4 Trials

D4
D3
A2
K1
K2

7
0.2155
0.2155
0.2155
0.2155
0.2145
1.0765
0.2153
0.001
0.2155
0.2145
0.2155
0.2155
0.2155
1.0765
0.2153
0.001

5
2.11
0
0.577
0.4299
0.7071

%AV
R&R (Gage Capability)
%R&R
PV (Part Variation)
%PV
TV (Total Variation)

0.0%
0.0006
82.3%
0.0004
56.8%
0.0007

0%
68%
47%

Conclusions / Recommendations
Gage system needs improvement
Gage may need maintenance, redesign, or better clamping

# Parts

#Trials
10

Calculate GageR&R using Anova

Anova Source
Appraiser

df

SS
1

MS
-4.4473

#Ops
5

With Interaction
Without Interaction
P
P
F
F
Err:502 -88.99934
Err:502
-4.4473 -8.999998

9
0.0000 1.834E-006 3.71E-006
9
4.4473 0.49414234 1227683
80
0.0000
0.0000
89
4.4473
0.0500
99 4.9728E-005

Parts
Appraiser x Part
Gage w AP Interaction
Gage w/o AP Interaction
Total

Estimate of Variance

Repeatability
Appraiser
AppraiserxPart
R&R
Part

0.00000
0.0988284472
0.0988283872
0.19766
0.04941

Std. Dev

0.000634429
0.314369921
0.314369826
0.444586591
0.222292714

5.15* Stdev

EV
AV
INT
R&R
PV
TV

1.00000 3.67E-005
0.00000

% Study
Variation

0.00326731
1.61900509
1.6190046
2.28962094
1.14480747
2.5598727

1.00000

% Contribution

0%
63%
63%
89%
45%

0%
40%
40%
80%
20%

Part by Appraiser Plot (Stacked)

0.2165

0.216

0.2155
Ave ragge
0.215

0.2145

0.214

0.2135
1

6
Part

Part by Appraiser Plot

0.2165

0.2165

0.216

0.2155
Ave ragge
0.215

0.2145

0.214

0.2135
1

4
51
Appraiser

10

10

App

Appraiser 2

Range of Parts by Appraiser (Stacked)

0.0035

0.003

0.0025

0.002
Range
0.0015

0.001

0.0005

0
1

6
Parts

Range of Parts by Appraiser

Range of Parts by Appraiser

0.0035

0.003

0.0025

0.002
Range
0.0015

0.001

0.0005

0
1

4Appraiser
5

10

Appraiser 2

10

App

0.0025

0.002
Range
0.0015

0.001

0.0005

0
1

4Appraiser
5

10

10

App

Appraiser 2

Instructions

1. Select 10 DIFFERENT parts and at least two "appraisers" and one gage
(If you don't use enough parts, part variation will be small and magnify the appraiser/equipment variation)
2. RANDOMLY, have appraisers measure each part at least twice
3. Then enter the results of each measurement in Cells C3:L7, C11:L15, C19:L23
4. The template will automatically calculate all of the values based on your data
5. Evaluate your measurement system based on %R&R and make adjustments as required.

Gage Repeatability and Reproducibility

Measurement is one common cause of variation. Gage R&R helps improve measurement systems
If repeatability (EV - Can the same person using the same gauge measure the same thing consistently)
is larger than reproducibility, reasons include:
1. Gage instrument needs maintenance
2. Gage needs to be redesigned
3. Clamping or location needs to be improved
4. Excessive within-part variation
If reproducibility (AV-can two appraisers measure the same thing and get the same result)
is larger than repeatability, reasons include:
1. Operator needs to be better trained in how to use and read gage
2. Calibrations on gage are not clear
3. Fixture required to help operator use gage more consistently
Gage System Acceptability
%R&R<10%
%R&R<30%
%R&R>30%

Gage System Okay (Most variation caused by parts, not people or equipment)
May be acceptable based on importance of application and cost of gage or repair
Gage system needs improvement (people and equipment cause over 1/3 of variation)

Verified using AIAG Measurement Systems Analysis 3rd Edition

Gage R&R Values

8
0.2145
0.2155
0.2145
0.2155
0.2145
1.0745
0.2149
0.001
0.2160
0.2145
0.2145
0.2155
0.2145
1.075
0.215
0.0015

Gage R&R Percentages

9
0.2160
0.2155
0.2160
0.2155
0.2160
1.079
0.2158
0.0005
0.2150
0.2160
0.2160
0.2155
0.2160
1.0785
0.2157
0.001

10
Sum
2.150
0.2150
0.2155
2.154
2.150
0.2150
0.2155
2.154 Xbar1
2.154
0.21522
0.2160
1.077
0.2154
Rbar1
0.001
0.00115
0.2145
2.155
0.2160
2.154
2.150
0.2150
0.2155
2.154 Xbar2
2.150
0.21525
0.2150
1.076
0.2152
Rbar2
0.0015
0.0015

Xbar3

Reference
0.215 <-Insert Reference Value Here
Bias
0.00022

Reference
0.215
Bias
0.00025

Reference
Bias

Rbar3

UCL represents the limit of the individual R's

Circle those beyond the limit.
Identify and correct causes
LCL = 0 D3=0 for up to 7 trials

d)

Average-Appraiser 1
Average-Appraiser 2
Average-Appraiser 3

10

Row 9

10

4
Appraiser
3

10

cked)

Range
1

10

10

4
Appraiser
35

10

10

4
Appraiser
35

y parts, not people or equipment)

pplication and cost of gage or repair
d equipment cause over 1/3 of variation)

10

Range Method

Range Method
Part
Appraiser 1
Appraiser 2
Range

2
12
11
1

GR&R

2.521008

Insert Process
Standard
Deviation
%GR&R

5.121849
49%

Insert Your Data Here

3
4
22
12
10
23
13
12
1
1
2

Page 13

Average

11
21
10

13.4
16 d2
3
1.19

Bias

Reference
Value
Value
Bias
4.9
5.0
4.8
5.1
5.0
5.1
5.1
4.9
5.2
5.1
5.1
5.0
4.9
4.9
4.8
5.0

-0.1
-0.2
0.1
0.0
0.1
0.1
-0.1
0.2
0.1
0.1
0.0
-0.1
-0.1
-0.2
0.0

tAverage/
Stdev(r)
Statistic/
n
Mean
Stdev
Stdev(b) critical
15
4.991333 0.124147 0.1125705 -0.298176
Bias
-0.0087
0.0290656
2.2064
95% Confidence
Lower
Upper
-0.071328 0.0539945
Bias Acceptable
Reference: AIAG MSA Version 3 pgs 85-88

Page 14

Bias

d2*/d2
df
3.55333
3.47193

g
10.8 d2*
df
d2
t crit 95%

2
1.41421
1
1.12838
4.303

3
1.91155
2
1.69257
3.182

ersion 3 pgs 85-88

Page 15

4
2.23887
2.9
2.05875
2.776

5
2.48124
3.8
2.3593
2.571

6
2.67253
4.7
2.53441
2.447

7
2.82981
5.5
2.70436
2.365

Bias

8
2.96288
6.3
2.8472
2.306

9
3.07794
7
2.97003
2.262

10
3.17905
7.7
3.07751
2.228

11
3.26909
8.3
3.17287
2.201

12
3.35016
9
3.25846
2.179

Page 16

13
3.42378
9.6
3.33598
2.16

14
3.49116
10.2
3.40676
2.145

15
3.55333
10.8
3.47193
2.131

16
3.61071
11.3
3.53198
2.12

Bias

17
3.66422
11.9
3.58788
2.11

18
3.71424
12.4
3.64006
2.101

19
3.76118
12.9
3.68896
2.093

20
3.80537
13.4
3.735
2.086

Page 17

Linearity

Trials

1
1
2
3
4
5
6
7
8
9
10
11
12

Average
Reference
Values
Bias
Range
bias=
slope*ref+b
Slope=
b=
Goodness of fit
Insert Process
Variation
Linearity
%Linearity

Part
3

2.7
2.5
2.8
2.4
2.3
2.3
2.7
2.6
2.5
2.5
2.6
2.45
2.53

2
10.1
9.98
9.9
9.5
10.5
10.1
10.1
10
10
9.9
9.8
9.8
9.97

15
14.99
14.85
14.89
14.8
15
15
15
15.1
15.3
15.6
15
15.04

36
36.4
36.5
36.5
36.5
36.5
36.5
36.2
36
36
36.5
36.8
36.37

49 <- Insert Your Data Here

49.5
48.9
Linearity evaluates a gaug
49
to measure accurately acr
49.8
Imagine measuring a base
49.6
1. at the grip
49.6
2. in the middle
49.6
3. and at the widest part
49.85
49.75
49.85
49.9
49.53

2.50
0.03
0.50

10.00
-0.03
1.00

15.00
0.04
0.80

36.25
0.12
0.80

49.00 <- Insert Known Reference Values He

0.53
1.00

-0.061643 0.013224 0.063135 0.275256 0.402529

0.009982
-0.086598
0.744645
17.66537
0.176339
1%
Linearity Plot

0.60
0.50
0.40
0.30
Bias
0.20
0.10
0.00
0.00

10.00

20.00

30.00

-0.10
Re ference Value

Page 18

40.00

50.00

60.00

Linearity

our Data Here

Linearity evaluates a gauge's ability

to measure accurately across a wide range
Imagine measuring a baseball bat:
1. at the grip
2. in the middle
3. and at the widest part

nown Reference Values Here

Page 19

Appraiser A
Part #

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38

Appraiser B

Appraiser C

Trial 1

Trial 2

Trial 3

Trial 1

Trial 2

Trial 3

Trial 1

Trial 2

1
0
1

1
0
1

1
0
0

1
0
1

1
0
1

1
0
0

1
0
1

1
0
0

Reference Results
Code
Trial 3 Reference Ref Value
1
1
0.476901
+
0
0
0.576459
0
1
0.544951
X
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
-

LSL
USL
0.45
0.55
1. Enter Spec Limits Above
2. Have 3 appraisers accept/reject 10+ p
3. Enter pass/fail in columns B-J
4. Enter Reference value in column L
5. Evaluate effectiveness columns AJ-AV

39
40
41
42
43
44
45
46
47
48
49
50

0
0
0
0
0
0
0
0
0
0
0
0
0 = Fail
1 = Pass

+ = within spec limits

- = outside spec limits
x = gray area around spec limits

%R&R Gray zone

25%
0.02500
er Spec Limits Above
e 3 appraisers accept/reject 10+ parts
er pass/fail in columns B-J
er Reference value in column L
uate effectiveness columns AJ-AV

A-B
1 2
1 1
0 0
1 1

3
1
0
0

B-C
1 2
1 1
0 0
1 -1

3
1
0
0

C-A
1 2
1
1
0
0
1 -2

3
1
0
0

A-REF
1 2 3
1 1 1
0 0 0
1 1 -2

B-REF
1 2 3
1 1 1
0 0 0
1 1 -2

C-REF
1 2 3
1 1 1
0 0 0
1 -2 -2

Crosstabulation
B
Total
A
0
1
0
4
0
4
1
0
5
5
Total
4
5
9

Crosstabulation
REF
Total
A
0
1
0
3
0
3
1
1
5
5
Total
4
5
9

C
0
4
0
4

1
1
4
5

REF
0
3
1
4

1
0
5
5

A
0
4
1
5

1
0
4
4

REF
0
3
2
5

1
0
4
4

B
0
1
Total

C
0
1
Total

Total
B
5
4
9

0
1
Total

Total
C
4
5
9

0
1
Total

Total
3
6
9
Total
3
6
9

around spec limits

Miss
Effectiveness
Rate
A 89%
11%
B 89%
11%
C 78%
22%
System
85%
15%
85%
Effectiveness
Acceptable
>= 90%
Marginal
>=80%
Unacceptable
<80%